Method and apparatus for welding a curved seam

Abstract

A system and method for welding flexible fabric is presented. A welding system for flexible fabric includes a welding machine with a roller and a user interface. The welding machine is adapted to weld a first fabric to a second fabric using a first heat. The roller on the welding machine can be used to roll at a first speed the first fabric and/and or the second fabric through the welding machine. Later, an operator of the welding machine through the user interface sends a single speed control signal to the welding machine. Response of the single speed control signal, the welding machine changes from the first heat to a second heat and also changes the speed of the roller from the first speed to a second speed.

What is claimed is: 
     
       1. A welding system for welding two piece of fabric comprising:
 a fabric welding machine; 
 a conveyer table adapted to feed an non-welded sidewall fabric to the welding machine at a first speed; 
 a turntable adapted to rotate to feed an non-welded second fabric to the welding machine at the first speed so that an edge of the second fabric overlaps an edge of the sidewall fabric; 
 wherein the welding machine is stationary and is configured to weld the non-welded sidewall fabric to the non-welded second fabric using a first welding temperature as the non-welded sidewall fabric and the non-welded second fabric past through the welding machine at the first speed; 
 a main roller in the welding machine adapted to the roll sidewall fabric and the second fabric that have been welded together as a welded fabric through the welding machine at the first speed; 
 a controller logic configured to detect a single request for a change of a parameter at a user interface, and wherein when the controller detects the single request for the change of the parameter the controller is configured to change at least one of the group of: the first welding temperature to a second welding temperature, change the speed of the turntable so that the second fabric is delivered to the welding machine at a second speed that is different than the first speed, and change the speed of the conveyer table so that the first fabric is delivered to the welding machine at the second speed; and 
 a fabric feed assembly adapted to feed the non-welded sidewall fabric to the conveyer table, wherein the fabric feed assembly comprises:
 a fixed frame adapted to sit on a surface and not move; and 
 a movable platform adapted to hold the non-welded sidewall fabric; 
 
 wherein the fixed frame further comprises an alignment detection device configured to determine if an edge of the non-welded sidewall fabric is aligned with a predetermined location as the non-welded sidewall fabric is fed to the conveyer table and wherein an alignment adjustment logic is configured to cause the movable platform to move to align the edge of the non-welded sidewall fabric with the predetermined location when the edge of the non-welded sidewall fabric is not aligned with the predetermined location. 
 
     
     
       2. The welding system for welding two piece of fabric of  claim 1  wherein the user interface further comprises:
 a foot pedal, and wherein the controller logic is adapted to detect the request for a change of a parameter as a request for a change of speed upon a depression of the foot pedal. 
 
     
     
       3. The welding system for welding two piece of fabric of  claim 2  wherein:
 the controller logic is configured to determine the second speed as a speed proportional to an amount of depression of the foot pedal. 
 
     
     
       4. The welding system for welding two piece of fabric of  claim 1  further comprising:
 an linear actuator mechanically connecting the movable platform to the fixed fame, and wherein the alignment adjustment logic is configured to cause the linear actuator to move the movable platform relative to the fixed frame to align the edge of the non-welded sidewall fabric with the predetermined location when the edge of the non-welded sidewall fabric is not aligned with the predetermined location. 
 
     
     
       5. The welding system for welding two piece of fabric of  claim 4  wherein the alignment detection device is a photoelectric sensor. 
     
     
       6. A welding system for welding two piece of fabric comprises:
 a fabric welding machine; 
 a conveyer table adapted to feed an non-welded sidewall fabric to the welding machine at a first speed; 
 a turntable adapted to rotate to feed an non-welded second fabric to the welding machine at the first speed so that an edge of the second fabric overlaps an edge of the sidewall fabric; 
 wherein the welding machine is stationary and is configured to weld the non-welded sidewall fabric to the non-welded second fabric using a first welding temperature as the non-welded sidewall fabric and the non-welded second fabric past through the welding machine at the first speed; 
 a main roller in the welding machine adapted to the roll sidewall fabric and the second fabric that have been welded together as a welded fabric through the welding machine at the first speed; 
 a controller logic configured to detect a single request for a change of a parameter at a user interface, and wherein when the controller detects the single request for the change of the parameter the controller is configured to change at least one of the group of: the first welding temperature to a second welding temperature, change the speed of the turntable so that the second fabric is delivered to the welding machine at a second speed that is different than the first speed, and change the speed of the conveyer table so that the first fabric is delivered to the welding machine at the second speed; and 
 a chute for placement between the turntable and a rear side of the welding machine adapted to guide welded fabric from the welding machine onto the turntable. 
 
     
     
       7. The welding system for welding two piece of fabric of  claim 6  wherein the chute further comprises:
 a main surface area with a straight front side adjacent the welding machine, a straight rear side adjacent the turntable that is at least 6 times shorter than the straight front side; 
 a curved interior side that begins at a left side of the straight front side and ends at a left side of the straight rear side; and 
 a curved exterior side that begins at a right side of the straight front side and ends at a right side of the straight rear side. 
 
     
     
       8. The welding system for welding two piece of fabric of  claim 7  further comprising:
 a wall extending upward from the curved exterior side that is at 90 degrees to the main surface area; and 
 one or more rollers extending through openings in the wall so that the one or more rollers are adapted to roll welded fabric toward the turntable. 
 
     
     
       9. A welding system for welding two piece of fabric comprises:
 a fabric welding machine; 
 a conveyer table adapted to feed an non-welded sidewall fabric to the welding machine at a first speed; 
 a turntable adapted to rotate to feed an non-welded second fabric to the welding machine at the first speed so that an edge of the second fabric overlaps an edge of the sidewall fabric; 
 wherein the welding machine is stationary and is configured to weld the non-welded sidewall fabric to the non-welded second fabric using a first welding temperature as the non-welded sidewall fabric and the non-welded second fabric past through the welding machine at the first speed; 
 a main roller in the welding machine adapted to the roll sidewall fabric and the second fabric that have been welded together as a welded fabric through the welding machine at the first speed; 
 a controller logic configured to detect a single request for a change of a parameter at a user interface, and wherein when the controller detects the single request for the change of the parameter the controller is configured to change at least one of the group of: the first welding temperature to a second welding temperature, change the speed of the turntable so that the second fabric is delivered to the welding machine at a second speed that is different than the first speed, and change the speed of the conveyer table so that the first fabric is delivered to the welding machine at the second speed; 
 a table top wall adapted to receive the non-welded second fabric; 
 a table side wall extending downward around an entire perimeter of the table top wall; and 
 a trough formed at a lower end of the table side wall and extending continuously along the entire lower end of the table side wall, wherein the trough is formed as a chamber with an opening at a top of the chamber adapted to receive welded fabric that overhangs the table top wall and table side wall. 
 
     
     
       10. The welding system for welding two piece of fabric of  claim 9  wherein the table top wall is round and the table side wall is cylindrical in shape. 
     
     
       11. The welding system for welding two piece of fabric of  claim 10  wherein the trough further comprises:
 a lower trough wall that is flat and has an circular outside bottom wall edge and a circular inside bottom wall edge, wherein the inside bottom wall edge is attached to the lower end of the table side wall and is formed at 90 degrees to the table side wall; and 
 a tapered trough wall that has a circular tapered wall edge that is round, wherein the circular tapered wall edge is attached to the outside bottom wall edge and wherein the tapered trough wall and the lower trough wall are formed with an obtuse angle at the circular tapered wall edge. 
 
     
     
       12. A welding system for flexible fabric comprising:
 a welding machine adapted to weld a first fabric to a second fabric using a first heat; 
 a roller on the welding machine adapted to roll at a first speed at least one of group of: the first fabric and the second fabric through the welding machine; 
 a user interface adapted to send a single speed control signal to the welding machine in response to a single action by an operator of the welding machine; 
 wherein in response of the single speed control signal the welding machine changes from the first heat to a second heat and the welding machine changes the speed of the roller from the first speed to a second speed; 
 a turntable with a flat upper surface adapted to deliver the second fabric to the welding machine at a same rate as the roller on the welding machine; and 
 a chute adapted to guide welded fabric from the welding machine onto the turntable. 
 
     
     
       13. The welding system of  claim 12  further comprising:
 a conveyer table comprising: 
 a conveyer belt adapted to deliver the first fabric to the welding machine at a same rate as the roller on the welding machine. 
 
     
     
       14. The welding system of  claim 13  further comprising:
 an alignment device adapted to align an edge of the first fabric with a reference point as the first fabric is moved onto the conveyer belt. 
 
     
     
       15. The welding system of  claim 12 , wherein the turntable further comprises:
 a trough adapted to receive excess welded fabric that does not fit on an upper surface of the turntable. 
 
     
     
       16. The welding system of  claim 12  wherein the user interface is a foot pedal.